Technological and Operational Requirements for the Peter Imhof, Polycompound AG Hans-Ulrich Siegenthaler, Kneading Experts GmbH Table of Contents 1. Typical Nanomaterials in the Compounding Step 2. Process Step and Requirements in the Compounding Plant 3. Technical Solutions 4. Application and Experiences 5. Handling of Nanomaterials 6. Summary 1
Typical Nanomaterials in the Compounding Step Nanoclay Nanosilver Carbon Nanotubes (CNT) Flame Retardant or Flame Retardant Synergist Graphene.... Mixing, Extrusion and Compounding Mixing Principles: - Distributive Mixing statistically homogeneous distribution of particles - Dispersives Mixing breaking agglomerated particles apart 2
Mixing, Extrusion and Compounding Dispersive and Distributive Mixing Distributive Mixing poor good Dispersive Mixing good poor Mixing, Extrusion and Compounding Aggregates 5-50 µm Primary Particles nano - 5 µm Agglomerates 50-1000 µm 3
Effect of chemistry vs. processing on dispersion 8 µm Particle > 3000 Platelets Chemistry Chemistry/Processing Processing Tactoids/ Intercalants Dispersion Courtesy of Southern Clay Products Partial Dispersion Dispersion Tactoids/ Intercalants Tactoids/ Intercalants Nanoclay dispersion/distribution mechanism Particles Shear Apart Distributive mixing Platelets Peel Apart Dispersive mixing Courtesy of Southern Clay Products 4
Mixing, Extrusion and Compounding Physical Principles: - Grinding - Shear Forces = [ 1/sec ] - Folding relaxation réorientation Mixing, Extrusion and Compounding Overview Batch vs. Continuous Processes Roller Mill Batch Banbury Mixing in the Viscous Phase Screw based Single Screw Oscillating Single Screw Continuous Twin Screw Multi Screw Rotor based 5
Mixing, Extrusion and Compounding : - Oscillating Single Screw (Buss, X-Compound, etc.) - Twin Screw Extruder (i.e. Coperion, Bertorff, Leistritz, etc.) - Multi Screw Extruder (i.e. Extricom, Entex, etc.) Mixing, Extrusion and Compounding Overview Batch vs. Continuous Processes Roller Mill Batch Banbury Mixing in the Viscous Phase Screw based Single Screw Oscillating Single Screw Continuous Twin Screw Multi Screw Rotor based 6
Process Design Typical Process Steps: Melting Deagglomeration (dispersive Mixing) Wetting Distribution (distributive Mixing) Homogenisation Deaerating / Degassing Filtration Shaping based on Phyllosilicates, Nanoclays Application Area Increased of stiffness at the same level of toughness Increased heat resistance Reduced permeability for oxiygen and water vapour Improved solvent resistance Improved surface properties Improved flow behaviour Flame retardant synergist Bentonite 7
Intercalation and Exfolation of Layers Intercalation and Exfolation of Layers Agglomerates Individual layers exvolated 8
Masterbatch vs. Compound: Concept STEP-1 Production of Nano-Masterbatch 50% STEP-2 Compound without Nanoclay Compound (Basis Nanoclay) Compound (Basis Nano-Masterbach) Masterbatch vs. Compound: Results ZUGPRÜFUNG 9
Masterbatch vs. Compound: Dispersion MB 1 MB 2 E-HDPE-10MB1 E-HDPE-10MB2 Nanocomposite based on Carbon Nanotubes (CNT) Application Area Increased electrical conductivity Increased mechanical properties Flame retardant synergist MWNT 10
Dispersion Agglomerates 0.4mm Diameter: 10-15 nm Length: 1µm Number of Tubes: 5-15 Masterbatch vs. Compound: Concept STEP-1 Production of CNT-Masterbatch 15-45% STEP-2 Compound (Base CNT) Compound (Base CNT-Masterbach) 11
Masterbatch vs. Compound: Dispersion Compound with CNT Compound with Masterbatch Handling of Nanomaterials: Safety 12
Handling of Nanomaterials: Safety Summary - The properties of the ingredients, the required process steps and the final quality of the product are influencing the choice of a system - The mixing process is the key. Appropriate configurations and process parameters allow the optimisation of quality/quantity of the product. - Proven scale-up procedures allow a save transfer from the lab scale of g/h to the big amounts of t/h - Increased requirements related to safety, reliability and the availability of the ingredients are challenging the science and industry - Some of the legilative procedures are not clarified yet 13